Dieser Beitrag stellt ein neues, hybrides Modell für die Entwicklung mechanischer und mechatronischer Systeme vor. Ziel ist es, die derzeitig bestehende Lücke zwischen abstrakten Funktionsmodellen und sehr konkreten, geometrieorientierten 3D-CAD-Modellen zu überbrücken. Das hier vorgestellte SkiPo-Modell beschreibt die Interaktionen zwischen den Komponenten eines Systems basierend auf den zugehörigen Material-, Energie- und Signalflüssen. Ergänzt wird diese abstrakte Darstellung mit Skizzen, die wichtige Konstruktionsentscheidungen in einer strukturierten, semistandardisierten Weise dokumentieren. Das Ziel dieser hybriden Modellierung ist es, die unvermeidbaren Iterationen zwischen abstrakten und sehr detaillierten Betrachtungen von mechanischen und mechatronischen Systemen in der frühen Phase der Produktentstehung zu unterstützen. In Erprobungen mit Studentengruppen zeigte sich, dass dieser Modellierungsansatz das Verständnis und die Kommunikation im Team fördern kann.

There is shift in the Architectural / Engineering / Construction and Facility Management (AEC&FM) industry toward performance-driven projects. Assuring good performance requires efficient and reliable performance control processes. However, the current state of the AEC&FM industry is that control processes are inefficient because they generally rely on manually intensive, inefficient, and often inaccurate data collection techniques. Critical performance control processes include progress tracking and dimensional quality control. These particularly rely on the accurate and efficient collection of the as-built three-dimensional (3D) status of project objects. However, currently available techniques for as-built 3D data collection are extremely inefficient, and provide partial and often inaccurate information. These limitations have a negative impact on the quality of decisions made by project managers and consequently on project success. This thesis presents an innovative approach for Automated 3D Data Collection (A3dDC). This approach takes advantage of Laser Detection and Ranging (LADAR), 3D Computer-Aided-Design (CAD) modeling and registration technologies. The performance of this approach is investigated with a first set of experimental results obtained with real-life data. A second set of experiments then analyzes the feasibility of implementing, based on the developed approach, automated project performance control (APPC) applications such as automated project progress tracking and automated dimensional quality control. Finally, other applications are identified including planning for scanning and strategic scanning.

There is shift in the Architectural / Engineering / Construction and Facility Management (AEC&FM) industry toward performance-driven projects. Assuring good performance requires efficient and reliable performance control processes. However, the current state of the AEC&FM industry is that control processes are inefficient because they generally rely on manually intensive, inefficient, and often inaccurate data collection techniques. Critical performance control processes include progress tracking and dimensional quality control. These particularly rely on the accurate and efficient collection of the as-built three-dimensional (3D) status of project objects. However, currently available techniques for as-built 3D data collection are extremely inefficient, and provide partial and often inaccurate information. These limitations have a negative impact on the quality of decisions made by project managers and consequently on project success. This thesis presents an innovative approach for Automated 3D Data Collection (A3dDC). This approach takes advantage of Laser Detection and Ranging (LADAR), 3D Computer-Aided-Design (CAD) modeling and registration technologies. The performance of this approach is investigated with a first set of experimental results obtained with real-life data. A second set of experiments then analyzes the feasibility of implementing, based on the developed approach, automated project performance control (APPC) applications such as automated project progress tracking and automated dimensional quality control. Finally, other applications are identified including planning for scanning and strategic scanning.

<p>Throughout the development of this report there will be a brief explanation of what the actual Aircraft Design Process is and in which stages the methodology that the authors are proposing will be implemented as well as the tools that will interact to produce this methodology.</p><p>The proposed tool will be the first part of a methodology that, according to the authors, by integrating separate tools that are currently used in different stages of the aeronautical design, will promote a decrease in the time frame for the initial stages of the design process.</p><p>The first part of the methodology above, that is proposed in this project, starts by creating a computer generated aircraft model and analyzing its basic aerodynamic characteristics “Lift Coefficient” and “Induced Drag Coefficient”, this step will be an alternative to statistical and empirical methods used in the industry, which require vast amount of data.</p><p>This task will be done in several steps, which will transfer the parametric aircraft model to an input file for the aerodynamic analysis program. To transfer the data a “translation” program has been developed that arranges the geometry and prepares the input file for analysis.</p><p>During the course of this report the reader will find references to existing aircrafts, such as the MD-11 or Airbus 310. However, these references are not intended to be an exact computer model of the mentioned airplanes. The authors are using this as reference so the reader can relate what he/she is seeing in this paper to existing aircrafts. By doing such comparison, the author intends to demonstrate that the Parametric Model that has been created possesses the capability to simulate to some extend the shape of existing aircrafts.</p><p>Finally from the results of this project it is concluded that the methodology in question is promising. Linking the two programs is possible and the aerodynamic characteristics of the models tested fall in the appropriate range. None the less the research must continue following the line that has been discussed in this report.</p>

Throughout the development of this report there will be a brief explanation of what the actual Aircraft Design Process is and in which stages the methodology that the authors are proposing will be implemented as well as the tools that will interact to produce this methodology. The proposed tool will be the first part of a methodology that, according to the authors, by integrating separate tools that are currently used in different stages of the aeronautical design, will promote a decrease in the time frame for the initial stages of the design process. The first part of the methodology above, that is proposed in this project, starts by creating a computer generated aircraft model and analyzing its basic aerodynamic characteristics “Lift Coefficient” and “Induced Drag Coefficient”, this step will be an alternative to statistical and empirical methods used in the industry, which require vast amount of data. This task will be done in several steps, which will transfer the parametric aircraft model to an input file for the aerodynamic analysis program. To transfer the data a “translation” program has been developed that arranges the geometry and prepares the input file for analysis. During the course of this report the reader will find references to existing aircrafts, such as the MD-11 or Airbus 310. However, these references are not intended to be an exact computer model of the mentioned airplanes. The authors are using this as reference so the reader can relate what he/she is seeing in this paper to existing aircrafts. By doing such comparison, the author intends to demonstrate that the Parametric Model that has been created possesses the capability to simulate to some extend the shape of existing aircrafts. Finally from the results of this project it is concluded that the methodology in question is promising. Linking the two programs is possible and the aerodynamic characteristics of the models tested fall in the appropriate range. None the less the research must continue following the line that has been discussed in this report.

Cette thèse s’inscrit dans le cadre d’un projet industriel multi-partenaires ayant pour objectif le développement d’un robot mobile collaboratif (un cobot), autonome dans ses mouvements au sol, capable de réaliser l’inspection visuelle d’un aéronef, à la fois en phase de petite ou grande maintenance dans un hangar ou en phase de pré-vol sur le tarmac d’un aéroport. Le cobot est équipé de capteurs lui permettant d’effectuer ses tâches de navigation autonome, mais également d’un ensemble de capteurs optiques constituant la tête d’inspection : une caméra orientable Pan-Tilt-Zoom et un scanner 3D qui délivrent respectivement des données sous forme d’images 2D et de nuages de points 3D. L’objectif de la thèse est de développer des algorithmes d’analyse d’images 2D et de nuages de points 3D, afin d’établir un diagnostic sur l’état de l’avion et son aptitude à voler. Nous avons développé des algorithmes pour vérifier certains éléments de l’appareil, tels que valves, portes, capteurs, pneus ou moteurs, et également pour détecter et caractériser des dommages 3D sur le fuselage (impacts, rayures, etc.). Nous avons exploité dans nos algorithmes les connaissances a priori disponibles, en particulier le modèle 3D CAO de l’avion (un AIRBUS A320 dans le cadre de nos essais). Durant ces travaux de la thèse, nous avons pu répondre à deux besoins (parfois antagonistes) : développer des algorithmes d’inspection rapides et robustes, mais également répondre aux exigences spécifiques d’un projet industriel qui visait à développer un prototype opérationnel. Nous nous sommes attachés à développer des algorithmes les plus génériques possibles, de manière à ce qu’ils puissent être utilisés pour d’autres types d’inspection, tels que l’inspection de bâtiments ou de navires par exemple. Nous avons aussi contribué au développement du prototype (robot mobile équipé de capteurs) en développant le module de contrôle des capteurs d’inspection et en intégrant nos codes sur le robot avec les autres modules développés par les partenaires. Le prototype a fait l’objet de nombreux essais en hangar de maintenance ou sur tarmac. / This thesis makes part of an industry oriented multi-partners project aimed at developing a mobile collaborative robot (a cobot), autonomous in its movements on the ground, capable of performing visual inspection of an aircraft during short or long maintenance procedures in the hangar or in the pre-flight phase on the tarmac. The cobot is equipped with sensors for realizing its navigation tasks as well as with a set of optical sensors which constitute the inspection head: an orientable Pan-Tilt-Zoom visible light camera and a three-dimensional scanner, delivering data in the format of two-dimensional images and three-dimensional point clouds, respectively. The goal of the thesis is to propose original approaches for processing 2D images and 3D clouds, with intention to make a decision with respect to the flight readiness of the airplane. We developed algorithms for verification of the aircraft items such as vents, doors, sensors, tires or engine as well as for detection and characterization of three-dimensional damages on the fuselage. We integrated a-priori knowledge on the airplane structure, notably numerical three-dimensional CAD model of the Airbus-A320. We argue that with investing effort to develop robust enough algorithms and with the help of existing optical sensors to acquire suitable data, we can come up with non-invasive, accurate, and time-efficient system for automatic airplane exterior inspection. The thesis work was placed in between two main requirements: develop inspection algorithms which could be as general as possible and also meet the specific requirements of an industry oriented project. Often, these two goals do not go along and the balance had to be made. On one side, we were aiming to design and assess the approaches that can be employed on other large structures, for ex. buildings, ships. On the other hand, writing source code for controlling sensors as well as integrating our whole developed source code with other modules on the real-time robotic system, were necessary in order to demonstrate the feasibility of our robotic prototype.

Les travaux présentés dans ce manuscrit s’inscrivent dans le contexte de l’inspection automatisée d’assemblages mécaniques aéronautiques par vision artificielle. Il s’agit de décider si l’assemblage mécanique a été correctement réalisé (assemblage conforme). Les travaux ont été menés dans le cadre de deux projets industriels. Le projet CAAMVis d’une part, dans lequel le capteur d’inspection est constitué d’une double tête stéréoscopique portée par un robot, le projet Lynx© d’autre part, dans lequel le capteur d’inspection est une caméra Pan/Tilt/Zoom (vision monoculaire). Ces deux projets ont pour point commun la volonté d’exploiter au mieux le modèle CAO de l’assemblage (qui fournit l’état de référence souhaité) dans la tâche d’inspection qui est basée sur l’analyse de l’image ou des images 2D fournies par le capteur. La méthode développée consiste à comparer une image 2D acquise par le capteur (désignée par « image réelle ») avec une image 2D synthétique, générée à partir du modèle CAO. Les images réelles et synthétiques sont segmentées puis décomposées en un ensemble de primitives 2D. Ces primitives sont ensuite appariées, en exploitant des concepts de la théorie de graphes, notamment l’utilisation d’un graphe biparti pour s’assurer du respect de la contrainte d’unicité dans le processus d’appariement. Le résultat de l’appariement permet de statuer sur la conformité ou la non-conformité de l’assemblage. L’approche proposée a été validée à la fois sur des données de simulation et sur des données réelles acquises dans le cadre des projets sus-cités. / The work presented in this manuscript deals with automated inspection of aeronautical mechanical parts using computer vision. The goal is to decide whether a mechanical assembly has been assembled correctly i.e. if it is compliant with the specifications. This work was conducted within two industrial projects. On one hand the CAAMVis project, in which the inspection sensor consists of a dual stereoscopic head (stereovision) carried by a robot, on the other hand the Lynx© project, in which the inspection sensor is a single Pan/Tilt/Zoom camera (monocular vision). These two projects share the common objective of exploiting as much as possible the CAD model of the assembly (which provides the desired reference state) in the inspection task which is based on the analysis of the 2D images provided by the sensor. The proposed method consists in comparing a 2D image acquired by the sensor (referred to as "real image") with a synthetic 2D image generated from the CAD model. The real and synthetic images are segmented and then decomposed into a set of 2D primitives. These primitives are then matched by exploiting concepts from the graph theory, namely the use of a bipartite graph to guarantee the respect of the uniqueness constraint required in such a matching process. The matching result allows to decide whether the assembly has been assembled correctly or not. The proposed approach was validated on both simulation data and real data acquired within the above-mentioned projects.

A fundamental aspect to consider in factories is the transportation of the items at differentsteps in the production process. Conveyor belts do a great to bring items from point A topoint B but to load the item onto a working station it can demands a more precise and,in some cases, delicate approach. Nowadays this part is mostly handled by robotic arms.The issue encountered is that a robot arm extremity, its gripper, cannot directly instinctivelyknow how to grip an object. It is usually up to a technician to configure how andwhere the gripper goes to grip an item.The goal of this thesis is to analyse a problem given by a company which is to find a wayto automate the grasp pose synthesis of a new object with the adapted gripper.This automatized process can be separated into two sub-problems.First, how to choose the adapted gripper for a new object.Second, how to find a grasp pose on the object, with the previously chosen gripper.In the problem given by the company, the computer-aided design (CAD) 3D model of theconcerned object is given. Also, the grasp shall always be done vertically, i.e., the grippercomes vertically to the object and the gripper does not rotate on the x and y axis. Thegripper for a new object is selected between two kinds of grippers: two-finger paralleljawgripper and three-finger parallel-jaw gripper. No dataset of objects is provided.Object grasping is a well researched subject, especially for 2 finger grippers. However,few research is done for the 3 finger grippers grasp pose synthesis, or for gripper comparison,which are key part of the studied problem.To answer the sub-problems mentioned above, machine learning will be used for the gripperselection and a grasp synthesis method will be used for the grasp pose finding. However,due to the lack of gripper comparison in the related work, a new approach needsto be created, which will be inspired by the findings in the literature about grasp posesynthesis in general.This approach will consist of two parts.First, for each gripper and each object combination are generated some grasp poses, eachassociated with a corresponding score. The scores are used to have an idea of the bestgripper for an object, the best score for each gripper indicating how good a grasp couldbe on the object with said gripper.Secondly, the objects with their associated best score for each gripper will be used astraining data for a machine learning algorithm that will assist in the choice of the gripper.This approach leads to two research questions:“How to generate grasps of satisfying quality for an object with a certain gripper?”“Is it possible to determine the best gripper for a new object via machine learning ?”The first question is answered by using mathematical operations on the point cloud representationof the objects, and a cost function (that will be used to attribute a score), whileithe second question is answered using machine learning classification and regression togain insight on how machine learning can learn to associate object proprieties to gripperefficiency.The found results show that the grasp generation with the chosen cost function givesgrasp poses that are similar to the grasp poses a human operator would choose, but themachine learning models seem unable to assess grasp quality, either with regression orclassification.

Moving from a project-based to a product-based organization comes with its own challenges, which goes for most organizations when one business model is changed to another. These changes lead to uncertainties in the work for the engineers, where lead time increases and time for the projects. This master thesis aimed to evaluate the uncertainties' characteristics and set standardizations in the work process to optimize the workflow and reduce engineering hours spent per project. The goals set for this thesis formulated three research questions: RQ1: What characterizes a reduction of engineering uncertainties through product-based structures?  RQ2: How can current layout modules be converted into standardized product-based structures? RQ3: How can standardized layout modules ensure the reduction of engineering uncertainties throughout the product-development process? By examining a case company’s journey through this transition through a quantitative methodology, three cases that each follow the product development process were conducted to answer the three research questions. The results for this thesis indicated that the implementation of standards reduced lead time and overall inconsistency, thus contributing to a more efficient modelling environment for the engineers and consistent implementation of an adaptable model for PDM integration. Implementing a design for assembly methodology proved to be a successful choice in reducing the assembly time for the engineers. An evaluation of the results indicates that only 34% of the engineering hours currently spent on conducting customer-based layout routings for the case company would be necessary when utilizing the standardized modules. / Att övergå från ett projektbaserat till ett produktbaserat bolag kan leda till vissa motgångar då övergången innebär förändringar i struktur och produktion. Dessa motgångar uppstår för en majoritet av bolag som implementerar denna övergång, där förändringar inom organisationen leder till ett antal osäkerheter i arbetet för ingenjörer som ökad ledtid och tidsåtgång för projekt. Målet med denna studie är att utvärdera vilka osäkerheter som uppstår och att standardisera arbetsprocessen för att optimera arbetsflödet och reducera tidsåtgång för ingenjörer per projekt. Målen för denna studie har genererat tre forskningsfrågor: FF1: Vad karaktäriserar en reducering av ingenjörsosäkerheter genom produktbaserade strukturer? FF2: Hur kan nuvarande layout moduler konverteras till standardiserade produktbaserade strukturer? FF3: Hur kan standardiserade layout moduler säkerställa reduktion av ingenjörsosäkerheter genom produktutvecklingsprocessen? Genom att undersöka ett fallföretags resa genom övergångsprocessen med en kvantitativ metodologi, genererades tre fall som följde produktutvecklingsprocessen för att utförligt svara på forskningsfrågorna. Resultaten för denna studie indikerar att implementeringen av standarder reducerar ledtid och övergripande inkonsekvens, vilket därmed bidrar till en mer effektiv konstruktionsmiljö för ingenjörerna, samt en mer konsistent implementering av en tillämpbar modell för PDM integrering. Implementeringen av design för sammanställnings metodologi visade sig vara ett lyckat val i att reducera sammanställningstid för ingenjörerna. En utvärdering av resultaten visar att endast 34% av den tid det tar för fallföretaget i dagsläget att utföra en fullständig ”layout routing” är nödvändig när standardiserade moduler tillämpas.

This diploma thesis primarily deals with the transmission error issue which is one of the dominant sources of vibration in gear pairs and transmission systems. The vibrations subsequently generate noise which is often subjected to increasingly stricter demands across the industry, including the automotive one. It turns out that reducing the peak-to-peak value of the transmission error has a beneficial effect on the vibro-acoustic properties of gears and gear pairs. This thesis aims to determine the transmission error under static conditions, since a gear pair with a low static transmission error is a good assumption for a low transmission error even under dynamic effects. The resulting values of the transmission error can be influenced already during the design of the gear macro-geometry. It is also suitable to apply micro-geometric adjustments – modifications to the gear teeth. For this reason, the search part of the thesis is dedicated to theoretical knowledge, especially concerning the geometry of gears, modifications of teeth and the overall transmission error and its determination. The transmission error can be determined in several ways, including a technical experiment. However, due to time and financial reasons, this is not always possible, and therefore, the possibility of using numerical simulations is offered. In this thesis, the approach using stress-strain quasi-static contact analysis using the finite element method in Ansys Workbench software is used. The advantage is, among other things, a good comparability of results. The input to the FEM analysis is 3D CAD geometry – in this case, it is specifically a helical gear pair with parallel axes. The model/assembly of this gear pair is created in PTC Creo software fully parametrically, so it is possible to generate arbitrary gear pair configurations by changing the input parameters, which significantly saves time. At the end of this diploma thesis, the stress-strain analysis of various gear configurations is evaluated, with respect to the equivalent stress and contact pressure. Furthermore, the static transmission error – its graphs and peak-to-peak values – is determined from FEM analyses for different gear geometry, including tooth modifications, and for various loading torques. Last but not least, the effects of contact/overlap ratio and centre distance are evaluated.